Nesting transportable wine barrel rack

ABSTRACT

A wine barrel rack system may include single barrel cradles ( 500 ) (or alternatively hardware for constructing such single barrel cradles), which may include two wedge plate bodies ( 504 ), each having upper barrel contact surfaces ( 508   a,    512   a,    430 ) configured to contact and support a single barrel (BA) in an upper tier at two or more locations. The wedge plate bodies ( 504 ) also include lower barrel contact surfaces ( 510   a,    514   a,    430 ) configured to contact and be supported by two barrels in a lower tier relative to the single barrel cradle. The wedge plate bodies ( 504 ) can be curved upward to cause the upper barrel contact surfaces to both contact a same upper tier barrel and to orient the lower barrel contact surfaces to contact the two lower tier barrels when the upper and lower tiers are offset in a staggered stacking configuration. Methods and systems are described.

CROSS-REFERENCE TO RELATED APPLICATIONS

The current application claims the benefit of the filing date of U.S. patent application Ser. No. 15/360,924, filed Nov. 23, 2016 and also of U.S. provisional patent application Ser. No. 62/426,186, filed Nov. 23, 2016, both of which are incorporated in their entirety by reference herein.

TECHNICAL FIELD

The invention relates most generally to barrel racks, and more particularly to wine barrel racks, and still more particularly to a compact, nestable, and economically transportable wine barrel rack system having discrete barrel cradle assemblies for stacking either identically or differentially sized barrels in a staggered stacking configuration, while providing access to barrel bungs at all levels. In some stacking configurations, seismic stability can be enhanced with seismic straps.

BACKGROUND

In wine production, when fermentation has been completed and after large solids have been removed by racking, the young wine usually needs time for the acids, alcohol, tannins, and glycerin to knit together, to harmonize. Accordingly, it is a traditional practice to barrel age and store the wine for a period of time. This can be accomplished using a number of different kinds of vessels or containers, such as stainless steel tanks, cement vats, glass carboys, or, in most instances, wood barrels. The traditional wood barrel material is oak (indeed, nearly all fine wines, almost without exception, are aged in oak) because it adds depth and complexity by adding phenols and oak tannins to the wine, and thereby adds new bouquet and flavor dimensions. Aging in oak also softens grape tannins, increases volatile acidity and total acidity, and lowers pH. Stored the right amount of time, wine aged in oak barrels is generally considered to be improved.

In consequence, large scale producers often keep hundreds to many tens of thousands of barrels in storage in production and storage facilities, generally either in barrel rooms or wine caves. The racks, however, cover a considerable amount of floor space. Furthermore, they are generally assembled by welding square steel tubing with steel bars to make unitary, assembled, rigid and fixed racks of the kind taught by Ray, U.S. Pat. No. 3,476,260, which shows a wine rack design that dominates the industry at present. See, for instance, the various models offered at the website links by the following major current-day manufacturers:

http://www.topcoproducts.com/

http://www.westernsquare.com/breweries_and_distillieries/brewery_barrel_racks.html

http://shop.carolinawinesupply.com/wine-barrel-racks_c34.htm

http://barrelsandracks.com/racks/

http://www.rmswinebarrelracks.com/wine-barrel-racks/

http://barrel-racks.com/?page_id=18

http://shop.carolinawinesupply.com/Wine-Barrel-Racks_c34.htm

http://barrelsandracks.com/racks/

From these, it will be seen that the rack dominant in the industry is a rigid square steel tube welded structure based on structural chocks welded onto square tube steel frame structure. The tube members are all welded together, and the bent steel bars forming wedges that act as chock are welded onto the tubes. The smallest units for stacking systems generally hold two barrels and stack atop two barrels. Bottom units simply cradle two barrels on top. Even this smallest structure consumes considerable space when assembled and welded, and thus when shipped. And stacking for shipment simply means that a substantial portion of the shipping volume is occupied by empty space.

As the South Napa Earthquake of Aug. 24, 2014 revealed, when racks are severely damaged in earthquakes, they are not amenable to repair and generally must be replaced. Fabrication of the conventional and traditional racks is time consuming and shipments are expensive. High demand taxes the ability of manufacturers to meet winery schedules for the needed stackable, palletized and forklift compatible barrel racks. In the years immediately following the South Napa Earthquake, there were many shipments of replacement racks required to address the losses. Among other things, that earthquake highlighted the need for a more compact rack, easily manufactured, easily and economically transported, and also easily dismantled for removal and relocation.

SUMMARY

One or more aspects of the current subject matter may address or otherwise solve certain problems, which may include but are not necessarily limited to those discussed above and elsewhere herein, for example by providing a low cost, easily manufactured, easily transported, and easily on-site assembled barrel rack that includes nesting component parts that ship in compact packages.

Wine barrel racks consistent with implementations of the current subject matter may advantageously exploit known principles of strengthening thin sheet metal panels by introducing bends and cutouts in the panels. Thus, the barrel support function of what was previously provided by a very heavy and clumsy structure—rigid, unitary, preassembled square tubular steel wine barrel racks—may be provided by extremely lightweight structural members that can be shipped as modular packages, easily handled, carried, and moved by individuals having unexceptional (entirely ordinary) strength.

In one aspect, a wedge plate body has a first end and a second end, a first wedge body axis passing from the first end to the second end, and a second wedge body axis perpendicular to the first axis. A first upper barrel contact surface and a second upper barrel contact surface project (or are otherwise directed) upward from an upper surface of the wedge plate body. The first upper barrel contact surface is disposed near the first end and the second upper barrel contact surface is disposed near the second end. A first end contact surface axis passes through the first upper barrel contact surface and a second end contact surface axis passes through the second upper barrel contact surface. The first end contact surface axis and the second end contact surface axis lie in a same plane as the first wedge body axis and the second wedge body axis and are angled inward such that they intersect the second wedge body axis and each other above the upper surface. A first lower barrel contact surface and a second lower barrel contact surface project (or are otherwise directed) downward from a lower surface of the wedge plate body opposite the upper surface. The first lower barrel contact surface is disposed near the first end and the second lower barrel contact surface is disposed near the second end. The first lower barrel contact surface is directed approximately opposite the first upper barrel contact surface along the first end contact surface axis, and the second lower barrel contact surface is directed approximately opposite the second upper barrel contact surface along the second end contact surface axis.

In optional variations, the wedge plate body can have a substantially planar shape, and/or the wedge plate body can have a curved shape with mirror image symmetry about the second body axis.

In an interrelated aspect, single barrel cradle includes two wedge plates and at least on cross member attached to the two wedge plates at opposite ends of the at least one cross member. The single barrel cradle is configured to support a single upper tier barrel contacting the first upper barrel contact surface and the second upper barrel contact surface on each of the two wedge plates and being supported by two lower tier barrels. A first of the two lower tier barrels contacts the first lower barrel contact surface on each of the two wedge plates and a second of the two lower tier barrels contacts the second lower barrel contact surface on each of the two wedge plates.

In another interrelated aspect, elongate tubular steel members may span laterally between side rails and include bolting plates or flanges on each of their ends. The bolting plates may be coupled to the side rails in an angled orientation to form a cradle. Rubber support pads may be slotted to fit over the bolting plate edges to cushion the cradle and distribute the barrel load. In this aspect, barrels in upper rows may be supported by barrel-specific (discrete) arcuate cradles that may be coupled or linked with chain or cable. Seismic tie downs may be employed to connect to a frame disposed over barrel bung holes so as to keep wine stored in the barrels entirely accessible even in the seismically secure, stacked storage configurations.

In another interrelated aspect, a wine barrel rack system may include first and second ground level side rails oriented generally parallel to one another. The side rails may be joined to one another with either sheet metal panel connecting members or tubular metal connecting members, the latter having bolting plates or flanges disposed on their ends. The rack may be assembled with nuts and bolts. Each of the side rails may include an upper bend forming a flange and a lower bend forming a flange so as to enhance the strength of the panels. In an embodiment, barrel shaped cutouts may be disposed on the upper edge of the side rails in a ground configuration of the rack, and on both upper and lower edges in an upper rack configuration. The cutouts may provide for barrel stacking in a generally stacked pattern, in which case upper cutouts in rails at upper levels are positioned generally directly above cutouts in the ground level rails and/or any other lower level of stacked barrels. They may also be configured for stacking in a staggered pattern.

The details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations. In the drawings,

FIG. 1 is an upper front left perspective view of the ground level configuration of the wine barrel rack of an embodiment of the present invention, shown supporting a single wine barrel;

FIG. 1A is a detailed upper front left perspective view taken along cut line 1A of FIG. 1;

FIG. 1B is an exploded view of the apparatus of FIG. 1;

FIG. 2A is an upper left front perspective view showing the sheet metal side rails and connecting panels of an embodiment of the inventive rack, nuts and bolts removed, disassembled, and poised for compact packing for transport or storage;

FIG. 2B is an upper front left perspective view showing the rack elements in a compact nested configuration;

FIG. 3A is a side view in elevation showing a sheet metal side rail after cutting but before bending, wherein the bend lines are shown with dashes;

FIG. 3B is the same view showing the side rail after the upper and lower bends have been made;

FIG. 3C is an end view in elevation of the side rails;

FIG. 4 is a top plan view of a panel of sheet metal showing the football-shaped cutouts which, when the side rails are cut long the dashed cut lines, will provide the arcuate depressions in the side rails for barrel support;

FIG. 5 shows the ground level configuration of the inventive rack holding two wine barrels and a stacked layer of the inventive rack atop the lowest level of barrels and upon which is a second row of barrels;

FIG. 6A is an upper front left front perspective view showing the stacked configuration;

FIG. 6B is an upper left front perspective view showing details of the connection between a side rail and a connecting panel;

FIG. 7A is an upper perspective view showing the stacked configuration disassemble, the nuts and bolts removed, and the side rails and connecting panels positioned for nesting in a compact packaged configuration for storage and transportation;

FIG. 7B shows the elements of the stacked configuration in a compact nested package for storage and transportation;

FIG. 8 is an upper front left perspective view of the ground level configuration of an embodiment of the wine barrel rack of the present invention, shown supporting a single wine barrel;

FIG. 9 shows the ground level configuration of the inventive rack holding four wine barrels and a stacked layer of the inventive rack atop the lowest level of barrels and upon which is a second row of barrels, partially filled;

FIG. 10A is a side view in elevation showing a sheet metal side rail after cutting but before bending, wherein the bend lines are shown with dashes;

FIG. 10B is the same view showing the side rail after the upper and lower bends have been made;

FIG. 10C is an end view in elevation of the side rails;

FIG. 11 is a top plan view of a panel of sheet metal showing the modified football-shaped cutouts which, when the side rails are cut long the dashed cut lines, will provide the arcuate depressions in the side rails for barrel support in an embodiment of the present invention;

FIG. 12A is a side view in elevation showing in another embodiment a sheet metal side rail of the upper (stackable) rack side rail after cutting but before bending, wherein the bend lines are shown with dashes;

FIG. 12B is the same view showing the side rail after the upper and lower bends have been made;

FIG. 12C is an end view in elevation of the upper (stackable) rack side rails;

FIG. 13 is a top plan view of a panel of sheet metal showing the modified and staggered football-shaped cutouts for the embodiment shown in FIG. 9, and FIGS. 12A-12C, which, when the side rails are cut long the dashed cut lines, will provide the arcuate depressions in the side rails for barrel support in this embodiment of the present invention;

FIG. 14 is a side view in elevation showing the ground level configuration and upper (stackable) rack configuration in use, combined so as to enable a stacked and staggered arrangement of barrels as viewed from the side of the rack (corresponding to the end of the barrels);

FIG. 15 is a schematic side view in elevation showing wine barrels stacked in a pyramidal configuration and further stabilized seismic strap using another embodiment of the inventive barrel rack;

FIG. 15A is a schematic side view in elevation showing the same embodiment with ground level rail ganged assemblies and a non-pyramidal barrel stacking scheme;

FIG. 16 is an upper perspective view showing the ground level configuration for the barrel rack system shown in FIG. 15;

FIG. 17 is an upper front perspective view showing an embodiment of an arcuate cradle employed in the present invention; and

FIG. 18 is a side view in elevation of the arcuate side panel component of the arcuate cradle'

FIG. 19 is a perspective view showing an embodiment of a cross member that may be employed to couple front and rear arcuate side panels;

FIG. 19A is a side view in elevation thereof;

FIG. 19B is a top plan view in elevation thereof;

FIG. 19C is an end view thereof;

FIG. 20 is a perspective view showing another embodiment of a cross member that may be employed to couple front and rear arcuate side panels;

FIG. 20A is an end view thereof;

FIG. 21 is an upper perspective view of an embodiment of a slotted rubber chock;

FIG. 21A is a side view in elevation thereof;

FIG. 21B is an end view in elevation thereof;

FIG. 21C is an end view of a slotted rubber chock adapted for use with the cross-member of FIGS. 20-20A;

FIG. 22 is a cross-sectional end view in elevation taken along section line 20-20 of FIG. 16;

FIG. 22A is a detailed view thereof;

FIG. 22B is a detailed cross-sectional end view in elevation of an alternative embodiment using the bolting plate of a cross-member for mounting a rubber chock; and

FIG. 22C is a detailed cross-sectional end view in elevation of an alternative embodiment using both the bolting plate of a cross-member and a wedge plate tongue for mounting a rubber chock.

When practical, similar reference numbers denote similar structures, features, or elements.

DETAILED DESCRIPTION

Referring first to FIGS. 1 through 14, wherein like reference numerals refer to like components in the various views, there is illustrated therein a new and improved nesting transportable wine barrel rack generally denominated 10 herein.

Looking now at FIG. 1, there is shown in perspective view the ground level configuration 10 of the barrel rack of the present invention, shown assembled and supporting a single barrel. The ground level of the rack includes a first side rail 12 and a second side rail 14 joined at their ends 12 a/12 b and 14 a/14 b, respectively, by first and second cross members, namely, connecting end panels 16, 18, as well as a medial cross member or connecting panel 20. The side rails are identical to one another, as are the connecting panels. Accordingly, in discussing these elements, attention is drawn to one as representative of the others.

Thus, it is seen that each ground level side rail 12/14 includes a plurality of upper arcuate cut outs 22, each suitable for supporting or cradling a wine barrel when paired with a cutout on the opposing side rail, as shown in FIG. 1.

Each side rail further includes an outwardly directed lower bend or flange 24, and an outwardly directed upper bend or flange 26, continuous but for interruptions at the upper arcuate cutouts, and thereby comprising a formed sheet.

The connecting panels 16/18/20 are each U-shaped with end legs 28 and through holes 30 that align with through holes 32 in the side rails for connection with nuts and bolts 34, 36, respectively. Washers 38 are preferably employed, for all the well-known reasons.

It will be noted, by reference to each of FIGS. 1-1B, that the connecting panels 16, 18, 20, are slightly less wide (i.e., have a lower profile) than the side rails 12, 14. Accordingly, and referring now to FIGS. 2A-2B, if the side rails are turned on their longitudinal (horizontal axis) such that the lower flange 26 and upper flange 26 are facing, they are positioned to couple around the connecting panels in a nested configuration 40 (FIG. 2B) for storage and transport.

The barrel rack system has distinct manufacturing advantages over the known art. This derives from the simplicity, rapidity, and economically advantageous method of manufacture. Because they are formed of sheet metal, and because the manufacturing process includes only a few quick fabrication steps, the barrel racks can be rapidly manufactured on demand, and therefore no appreciable inventory need be stored anywhere.

FIG. 4 shows a sheet metal panel 50 partially processed during manufacture of the ground-level rack elements. In this view, the sheet metal panel is shown marked along dotted cut lines 52 for cutting with a laser, water jet, bench (lever) shear, guillotine (squaring or power shear), etc. A plurality of football-shaped holes (i.e., prolate spheroid in longitudinal cross section) 54 have already been cut from the panel using, for instance, a laser or water jet, and bolt holes 56 have been punched or drilled. After the football holes are cut and the bolt holes drilled, the panel is cut along the cut lines 52 and then upper and lower flanges (26, 24, respectively, in FIGS. 1-2B) are bent using a press brake or, more preferably, a universal bending machine.

Connecting panels 16, 18, 20 are formed from a separate raw sheet of sheet metal, and then drilled and bent similarly.

FIGS. 5-7B show another embodiment 60 of the inventive rack, this embodiment adapted for stacking at either the ground level or at levels above ground level, including atop a row of barrels. Thus, when a ground level rack 10 is disposed on a cellar floor and a number of barrels WB are placed on the ground level rack, the stackable (upper) rack 60 may be placed atop the barrels on the ground level rack.

The stackable rack 60 includes first and second side rails 62, 62 joined at their ends 62 a/62 b and 64 a/64 b, respectively, by first and second connecting end panels 66, 68, and a medial connecting panel 70. The side rails are identical to one another, as are the connecting panels.

Each stackable side rail 62/64 includes a plurality of arcuate cut outs 72, each suitable for supporting or cradling a wine barrel when paired with a cutout on the opposing side rail, as shown in FIG. 5, and also suited for stacking atop barrels positioned below. Unlike the ground level embodiment, the stackable rails include arcuate cutouts on each longitudinal edge of the rail. Thus, the rails may be rotated about a longitudinal axis, and with the flange or bend 74 facing outward, the rail may be flipped over and used in an inverted orientation (as can the assembled rack).

As with the first embodiment, U-shaped connecting panels 66/68/70 again include legs 78 and through holes 80 that align with through holes 82 in the side rails for connection with nuts 84, bolts 86, and washers 88.

Forklift holes 90 may be provided in the side rails.

The rack elements are each preferably formed from stainless steel, and more preferably with 300 series austenitic stainless steel, though any of a number of kinds of stainless steel and aluminum panel kinds may be employed to provide a rack with sufficient structural integrity and corrosion resistance to handle the heavy loads borne by racks in which barrels are stacked 4 or more levels high in slightly acid and humid cellar environments.

The stackable rack is also capable of compact storage in nestable packs 100, thus making it fit for large shipping unassembled in large numbers so as to be able to meet the needs of an end user at low cost and in quick order.

In another embodiment of the present invention, shown in FIGS. 8-11, the ground level configuration 200, includes side rails 202, 204 joined near or at their ends, respectively 206 a/206 b and 208 a/208 b (208 b being concealed in FIG. 8), by first and second laterally disposed cross members 210, 212, and at least one (preferably several) medial cross support(s) 214. The side rails are identical to one another, as are the cross members.

Thus, it is seen that each ground level side rail 202/204 includes a plurality of arcuate cut outs 216, each suitable for supporting or cradling a wine barrel when paired with a cutout on the opposing side rail, as shown in FIGS. 8-9.

Each side rail further includes an outwardly directed lower bend or flange 218, and an outwardly directed upper bend or flange 220, continuous but for interruptions at the arcuate cutouts, and thereby comprising a formed sheet.

The end cross members 210/212 and medial cross members 214 are each fabricated from square or rectangular tube (steel, aluminum, alloys, etc.) with an integral and/or welded flange 222 and through holes that align with through holes in the side rails for connection with nuts and bolts 224, respectively, the holes concealed by the nut/bolts assemblies, but evident in the views. The cross members for the ground level configuration further include legs 226 to elevate the entire rack off the ground and provide clearance for water and wine to run freely out from under the assembly and for the forks of a forklift to fit under easily for easy and rapid movement of entire racks within a production facility.

This embodiment of the wine barrel rack of the present invention includes an enhanced cutout having notches 228 onto which chocks 230 with slots are disposed so as to provide support and cushioning in the arcuate cradle formed by the cutouts 216. The chocks are fabricated from a food grade resilient material, such as silicone or other suitable synthetic rubber product, so as to minimize any chance that the assembly will harbor microorganisms that might infect and destroy the beverage contained in the barrels.

FIG. 11 shows a sheet metal panel 240 partially processed during manufacture of the ground-level rack elements. In this view, the sheet metal panel is shown marked along dotted cut lines 242 for cutting with a laser, water jet, bench (lever) shear, guillotine (squaring or power shear), etc. A plurality of football-shaped holes 244 have already been cut from the panel using a laser or water jet, and bolt holes 246 have been punched or drilled. After the football holes are cut and the bolt holes drilled, the panel is cut along the cut lines and then upper and lower flanges (218, 220, respectively in FIGS. 8, 10A & 10C) are bent using a press brake or, more preferably, a universal bending machine.

Cross members 210, 212, 214 are formed from separate metal tubes and then drilled and provided with flanges.

FIG. 9 shows an upper (stackable) rack configuration 250 for use with the above described lower rack configuration. This upper rack configuration is adapted for stacking at levels above ground level, including atop a row of barrels. Thus, when the ground level rack 200 (FIG. 8) is disposed on a cellar floor and a number of barrels WB are placed on the ground level rack, the stackable rack 250 may be placed atop the barrels ground level barrels.

The upper (stackable) rack 250 is configured substantially identically to the ground level configuration with a few notable exceptions, clearly seen in FIG. 9, and better appreciated by reference to FIGS. 12A-14, where it is seen that the upper (stackable) rack 250 includes side rails 252, 254 joined near or at their ends, respectively 256 a/256 b and 258 a/258 b (258 b being concealed in FIG. 9), by first and second cross members 260, 262, and at least one (preferably several) medial cross support(s) 264. Notes should be taken that medial cross members 264 are secured at an angle such that the sides and top portions of the cross members are oriented at an angle generally coincident with the curved sides of a wine barrel. The side rails are identical to one another, as are the cross members.

Thus, it is seen that in this embodiment each upper rack side rail 252/254 includes a plurality of upper and lower arcuate cut outs 266 a and 266 b, respectively, the upper arcuate cut outs adapted for supporting or cradling a wine barrel and bearing its weight, and the lower cut outs 266 b adapted for placement over a wine barrel. The upper and lower cutouts are arranged in a staggered pattern, such that the lower cutouts re disposed under and generally centered between two adjoining upper cutouts.

Each side rail further includes an outwardly directed lower bend or flange 268, and an outwardly directed upper bend or flange 270, continuous but for interruptions at the arcuate cutouts, and thereby comprising a formed sheet.

The end cross members 260/262 and medial cross members 264 may be fabricated from square or rectangular tube (steel, aluminum, alloys, etc.) with an integral and/or welded flange 272 and through holes that align with through holes in the side rails for connection with nuts and bolts 274, respectively, the holes concealed by the nut/bolts assemblies, but evident in the views. The cross members for the upper rack configuration do not include legs to elevate the rack off the ground, as clearance for water and wine, for the forks of a forklift, and the like, is inherent in the elevated disposition of the rack when placed atop a wine barrel.

This embodiment of the wine barrel rack of the present invention also includes the enhanced cutout having notches 278 onto which upper chocks 280 a and lower chocks 280 b, each with slots, are disposed. Again, these provide support and cushioning in the arcuate cradle formed by the cutouts 266 a/266 b.

FIG. 13 shows a sheet metal panel 290 partially processed during manufacture of the ground-level rack elements. In this view, the sheet metal panel is shown marked along dotted cut lines 292 for cutting. Football-shaped holes 294 for the enhanced cutouts have already been cut from the panel using a laser or water jet, and bolt holes 296 have been punched or drilled. After the football holes are cut and the bolt holes drilled, the panel is cut along the cut lines and then upper and lower flanges (268, 270, respectively in FIGS. 9, 12A & 12C) are bent.

Cross members 260, 262, and 264 are formed from separate metal tubes and then drilled and provided with flanges.

FIG. 14 shows a three-level stack including the ground level configuration and two upper rack configurations as might be found in a wine barrel room or wine cave. This view features a staggered arrangement of barrels (as viewed from the side or barrel end view of the rack, along a barrel axis BA that is at least approximately perpendicular to a transverse axis TA). The staggered arrangement of barrels WB can advantageously facilitate access to a bung 1400, which may be disposed at a apex of the barrel WB. This view also shows how optional vertical supports 300 may be installed at the ends 256 a/256 b, and 258 a/258 b of the side rails to provide further support and stability to the rack assembly.

In some implementations of the current subject matter, exemplary features of which are illustrated in FIGS. 15-16, the ground level configuration (e.g. a ground level supporting structure 400) may include front and rear side rails 402, 404 or other transverse members that extend or are configured to be joined with other such members to extend along a transverse axis TA that is at least approximately perpendicular to a barrel axis BA oriented parallel to the axis of rotation of barrels WB (which refers generally herein to stackable/storable items with a round cross-section) being stored. The side rails 402, 404 or other transverse members may be joined by a plurality of cross members 406, which may be generally aligned with the barrel axis BA. Alternatively or additionally, the cross members 406 may be oriented at some angle relative to the barrel axis BA. In some implementations of the current subject matter, the cross members 406 may be multiple similar or even identical rails or the like, which may be shipped together with the other parts described herein or sourced separately. The front side rail 402 and the rear side rail 404 may be identical to one another, and, as noted above, may be continuous single rail members or, alternatively, constructible from smaller modular pieces to allow expansion of a stacking system along the transverse axis TA to an extent desired (or to fit an available storage space). Thus, it is seen that each ground level side rail 402, 404 may include a plurality of cut outs 408, in opposing paired relationships, when the side rails 402, 404 are joined by the cross members 406, with the cutouts 408 sized and shaped to accommodate a portion of a bottom of a wine barrel, as shown in FIG. 15. The cutouts may be arcuate in shape, though they need not be. In general, the cutouts 408 may be characterized as providing an indentation or other supportive receiving area sized for receiving a barrel or other item with a round cross section and generally providing resistance to rolling of this barrel or other item along the transverse axis TA.

Each side rail 402, 404 may also further include an outwardly directed lower bend or flange 410, and an outwardly directed upper bend or flange 412, which may be continuous but for interruptions at the cutouts 408, such that the side rails 402, 404 may be conveniently and inexpensively formed by a sheet metal stamping process or the like using a single piece of sheet metal for each such rail 402, 404.

The cross members 406 for use in this embodiment may be fabricated from metal tubing 414. As shown in FIGS. 19-20, the tubing 414 may optionally have a square or rectangular cross section and may include an integral and/or welded bolting plate or flange 416 and through holes 418 that align with through holes in the side rails 420 for connection with nuts and bolts 422. Other configurations of the cross members 406 are also within the scope of the current subject matter. For example, other cross sections (circular, oval, etc.) are also possible for the tubing 414 Solid steel or aluminum blocks may be cut to accommodate the flange and panel of the side rail and to bolt onto the side rails and thereby to act as legs 424 that elevate the side rail slightly above ground level, again, providing clearance for water and wine to run freely out from under the assembly and for the forks of a forklift to fit under for easy and rapid movement of loaded racks.

As indicated above, the side rail cutouts may be any of a number of shapes, including arcuate (as in an earlier-described embodiment) or more polygonal in side view. In a preferred embodiment, the region of the side rail cutout may include inwardly angled mounting tongues 426 having an upper edge 427 and proximate an outer edge 428. A slotted resilient mounting pad or chock 430 may be placed on the tongue. In some examples, a mounting chock 430 may be formed of a food grade resilient material. Moreover, the tongue may be spaced apart slightly from the cutout outer edge so as to allow some compression of the mounting chock 430 when under load from a barrel or stack of barrels. From the views it will be seen that in an embodiment, the edge of the bolting plate 416 may be oriented and generally aligned with the tongue when the cross member bolt holes 418 are brought into alignment with the side rail bolt holes 420. The chocks 430 may, in some implementations of the current subject matter, be formed or otherwise made of any of a food grade rubber, a synthetic rubber, a polymeric block 432, or the like with a slot 434 for placement over the tongue upper edge 427 or the bolting plate or a combination of the tongue and bolting plate (see further at FIGS. 21-21C). A wider slot 436 may be provided when the chock is to be disposed over a bolting plate and wedge plate tongue when those features are approximated at their sides in two metal plate layers, as shown in FIG. 22C.

As can be seen by reference to FIGS. 15-16, the ground level side rails may be assembled in modular units with simple nuts-and-bolts couplings of the structural elements. When motorized drills and sockets are utilized, full assembly of each unit can be accomplished in a matter of only a few minutes. FIG. 15 shows an example of the ground level assembly standing alone and the wine barrels stacked upon the assembly in a pyramidal scheme. Tie down straps TDS can be employed to provide enhanced stability in seismically active areas, such as California, Oregon, Chile, Italy, Greece, Japan, Mexico, and New Zealand. In more quiescent areas, staggered stacking at higher levels and on ganged ground level assemblies can be achieved (FIG. 15A).

Thus, and still referring to FIG. 15A, units can be joined or ganged in aligned and contiguous end-to-end groups by joining the ends 440 of the rails, for example using a connecting panel 442 or the like. Thus, barrels WB may be stacked in the staggered stacking configuration shown in FIG. 15 not only over the middle portions of the assembled units 400, but carried over onto and above the joined end portion of coupled units.

While many, if not most, wine producers may use barrels of identical size and construction for wine storage, barrels are handmade and inherently imperfectly sized. Further, some winemakers may wish to experiment with different barrels from different coopers. Previously available rigid rails systems may not be advantageously adapted for use on rows of barrels that include any barrel departing from the size of adjoining barrels. Thus, and referring now to FIGS. 17-18, some implementations of the current subject matter may further facilitate stacking in a staggered stacking configuration as well as stacking of differently sized barrels. This may be achieved using upper (stackable) rack elements formed as discrete, single-barrel cradles 500, each adapted for supporting only a single barrel above the single-barrel cradle 500 while resting in a supporting relationship on tow lower tier barrels. This implementation is further described below.

Each cradle 500 may include opposing similarly shaped and optionally substantially planar metal wedge plates 502 joined by cross members 406, which may be similar or identical to those employed in the ground rail assembly. In certain implementations of the current subject matter, the wedge plates may have an elongate shape having mirror image first and second ends 504, 506 configured with upper and lower angled mounting tongues 508, 510, and 512, 514, respectively, at their ends, and each having an edge 508 a, 510 a, 512 a, 514 a generally in line with the respective upper edge 516 and lower edge 518 of the wedge plate. The mounting tongues may be defined by slots cut into the upper and lower edges of the wedge plate 502. The arcuate shape includes an upper edge radius slightly larger than the radius of a standard 60-gallon wine barrel or a 53-gallon whiskey barrel between the quarter hoop and head hoop circumferences. A mounting chock 430 (optionally having similar properties to those described above for use with the side rails 402, 404 of the ground level support structure) may be disposed on the edges of each tongue so as to cushion barrels above and below (e.g. as shown in FIG. 15). The wedge plates may be fabricated from any of a number of suitable metals, though stainless steel and aluminum may be advantageous. Aluminum has natural corrosion resistance, but this may be enhanced with coatings, including those that simply stabilize aluminum oxide.

The above-described implementation (shown in various aspects in FIGS. 15 through 22C) is an example of a more generalizable inventive concept in which a staggered arrangement of stacked barrels are supported by a modular structure that includes singe barrel cradles each supporting a barrel in an upper tier through contact with two offset barrels in a lower tier. FIG. 15 shows this staggered arrangement of stacked barrels with three tiers I, II, and III. The lowest tier I includes 3 barrels, while the middle tier II includes 2 barrels and the top tier III includes one barrel. In this and various arrangements consistent with implementations of the current subject matter, the single barrel cradles 500 (of which there are three shown in FIG. 15) may be described as intermediate between a barrel in an upper tier and two barrels in a lower tier, where the terms upper and lower are relative to the given single barrel cradle 500. As shown in FIG. 15, each single barrel cradle 500, which can include two wedge plates 502 connected by one or more cross members 406, includes contact surfaces directed into the upwardly curving part of the wedge plate and opposed contact points directed outward and opposite to the contact surfaces directed into the upwardly curving part. These contact surfaces are referred to in the implementations discussed above as mounting tongues 508, 510, and 512, 514, each have mounting tongue edges 508 a, 510 a, and 512 a, 514 a. At a more general level, the contact surfaces can be referred to as two (or at least two) upper barrel contact surfaces that are directed upward and configured to contact a single barrel disposed above and supported by the single barrel cradle and two (or at least two) lower barrel contact surfaces that are configured to contact two barrels disposed below and providing support to the single barrel cradle 500 and by extension the single barrel supported by the single barrel cradle 500.

With reference to FIG. 17 and FIG. 18, a first upper barrel contact surface 508 a and a second upper barrel contact surface 512 a project or are directed upward from an upper surface 516 of a wedge plate body 502. The wedge plate body can be considered to have a first end 504 and an opposite second end 506 and can optionally have a substantially planar shape along a first wedge body axis WBA1 that passes from the first end 504 to the second end 506. The wedge plate body 502 can also have a curved or otherwise upwardly angled shape with an at least approximately mirror image symmetry about a second wedge body axis WBA2 that is perpendicular to the first wedge body axis WBA1. As shown in FIG. 17 and FIG. 18, the upper surface or edge 516 of the wedge plate body can be curved. It could optionally be angled such that the shape of angling or curvature approximates the shape of a barrel to be supported.

The wedge plate body 502 can have a lower surface or edge 518 disposed opposite the upper surface or edge 516. The lower surface or edge 518 can be curved or angled in a manner that is at least approximately similar to the curvature or angling of the upper surface or edge 516. Near or at each of the first end 504 and the second end 506 respectively, the first upper barrel contact surface and the second upper barrel contact surface project or are directed upward with contact surfaces that may be approximately planar or otherwise curved or angled with an at least slightly convex upward shape. A first end contact surface axis CSA1 and a second end contact surface axis CSA2 can respectively be perpendicular to the first upper barrel contact surface 508 a and the second upper barrel contact surface 512 a or to a tangent of each of the first upper barrel contact surface 508 a and the second upper barrel contact surface 512 a (e.g. if the upper contact surfaces have some convex curvature or angling). The first end contact surface axis CSA1 and the second end contact surface axis CSA2 can be angled inward such that they intersect the second wedge body axis WBA2 above the upper surface or edge 516 of the wedge plate body 502.

On the lower surface or edge 518 at or near the first end 504 and second end 506, respectively, first lower barrel contact surface 510 a and a second lower barrel contact surface 514 a project or are directed downward and outward from the second wedge body axis WBA2, generally along the first end contact surface axis CSA1 and the second end contact surface axis CSA2, respectively in opposite directions from the first upper barrel contact surface 508 a and the second upper barrel contact surface 512 a. The first lower barrel contact surface 510 a and the second lower barrel contact surface 514 a can be generally flat or optionally convex or otherwise angled away from the lower surface or edge 518 such that the curvature or angling can be configured to match curvature of a barrel.

The wedge plate body 502 can include at least one mounting feature (e.g. bolt holes, one or more projections, or the like) configured to mate with one or more cross members 406 such that the one or more cross members can in turn couple to a second wedge plate body to form a single barrel mounting cradle 500 configured to rest on two lower tier barrels respectively contacting the first lower barrel contact surface 510 a and the second lower barrel contact surface 514 a and to support an upper tier barrel that contacts both of the first upper barrel contact surface 508 a and the second upper barrel contact surface 512 a. As noted above, the first upper barrel contact surface 508 a, the second upper barrel contact surface 512 a, the first lower barrel contact surface 510 a, and the second lower barrel contact surface 514 a can each have attached thereto a mounting chock 430, which may be formed of rubber or some resilient material.

In an alternative embodiment of the cross member 440, an upper side 442 of the bolting plate 444 may be elongated so as to obviate the need for a tongue in either the ground level side rails or the wedge plates, such that the elongated upper side 442 functions as the barrel support structure (see FIG. 22B). Alternatively, an elongate upper side may supplement and reinforce the side rail and wedge plate tongues by providing another layer of steel at the critical support point (see FIG. 22C). In this embodiment, the bolt hole orientation is again diagonal or otherwise oriented in combination so as to align the bolt plate upper edge 446 with the tongue upper edge 508 a, 510 a.

In still another embodiment, cross member 440 may include a bolting plate or flange having both an elongated upper side 442 and an elongated lower side 446, thereby obviating the need for a tongue on either the upper side or the lower side of the wedge plate.

Those with skill will appreciate that after transport in a nested configuration, the barrel rack of the present invention may be assembled using welds rather than using a nut-and-bolt assembly. The advantage of a potential rapid disassembly or reconfiguration is lost in such a case, but there is the concomitant advantage gained through the elimination of self-loosening nuts and bolt connections.

As will be appreciated from reference again to FIGS. 1 and 9, when the upper level rack member includes side rails that span across three or more lower barrels, any differential in the outer circumference of the lower barrels at the points of support will introduce a tilt in the rails. Accordingly, an advantage residing in an arrangement with separated upper cradles is to provide means to accommodate differentially sized barrels (with respect to circumference). Indeed, with such an arrangement, significant differences in barrel circumference can be accommodated.

Thus, it is seen that in embodiments, each upper cradle is adapted for resting on barrels in a lower course (whether ground level or above) and for supporting or cradling a wine barrel and bearing its weight. As with the embodiment using an upper rail configuration, the ground level rail and discrete cradle arrangement provides a staggered stacking pattern.

The above disclosure is sufficient to enable one of ordinary skill in the art to practice the invention, and provides the best mode of practicing the invention presently contemplated by the inventor. While there is provided herein a full and complete disclosure of the embodiments of this invention, it is not desired to limit the invention to the exact construction, dimensional relationships, and operation shown and described. Various modifications, alternative constructions, changes and equivalents will readily occur to those skilled in the art and may be employed, as suitable, without departing from the true spirit and scope of the invention. Such changes might involve alternative materials, components, structural arrangements, sizes, shapes, forms, functions, operational features or the like.

In the descriptions above and in the claims, phrases such as “at least one of” or “one or more of” may occur followed by a conjunctive list of elements or features. The term “and/or” may also occur in a list of two or more elements or features. Unless otherwise implicitly or explicitly contradicted by the context in which it used, such a phrase is intended to mean any of the listed elements or features individually or any of the recited elements or features in combination with any of the other recited elements or features. For example, the phrases “at least one of A and B;” “one or more of A and B;” and “A and/or B” are each intended to mean “A alone, B alone, or A and B together.” A similar interpretation is also intended for lists including three or more items. For example, the phrases “at least one of A, B, and C;” “one or more of A, B, and C;” and “A, B, and/or C” are each intended to mean “A alone, B alone, C alone, A and B together, A and C together, B and C together, or A and B and C together.” Use of the term “based on,” above and in the claims is intended to mean, “based at least in part on,” such that an unrecited feature or element is also permissible.

The implementations set forth in the foregoing description do not represent all implementations consistent with the subject matter described herein. Instead, they are merely some examples consistent with aspects related to the described subject matter. Although a few variations have been described in detail herein, other modifications or additions are possible. In particular, further features and/or variations can be provided in addition to those set forth herein. For example, the implementations described above can be directed to various combinations and sub-combinations of the disclosed features and/or combinations and sub-combinations of one or more features further to those disclosed herein. In addition, the logic flows depicted in the accompanying figures and/or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. The scope of the following claims may include other implementations or embodiments. 

What is claimed is:
 1. A wine barrel rack and support system, comprising: at least one ground level rack assembly including first and second ground level side rails oriented generally parallel to one another, said ground level rack assembly configured to support a plurality of barrels; a plurality of elongate cross-members having an elongate tubular portion with first and second ends, and cross-member flanges disposed on each of said first and second ends, where at least two of said cross-members are disposed between and connect said first and second ground level side rails; at least two upper level single-barrel cradles, each including first and second wedge plates affixed to at least two of said cross-members at said cross-member flanges, said wedge plates having an upper edge and a lower edge; and resilient mounting chocks disposed on either or both of said cross-member flanges and said wedge plates; wherein said first and second ground level side rails and said upper level barrel cradles each have a disassembled/nested configuration for storage and transport and an assembled configuration for supporting a plurality of wine barrels.
 2. The wine barrel rack and support system of claim 1, wherein each of said first and second ground level side rails comprise sheet metal panels having an upper bend forming a flange and a lower bend forming a flange, and having a plurality of upper cut outs shaped and sized to accommodate a portion of a wine barrel.
 3. The wine barrel rack and support system of claim 1, wherein said wedge plates include upper mounting tongues onto which said chocks are disposed.
 4. The wine barrel rack and support of claim 1, wherein said wedge plates include upper and lower mounting tongues on which said chocks are disposed.
 5. The wine barrel rack and support system of claim 1, wherein said mounting flanges and said cross-member flanges are approximated in a side-by-side layer and said chocks are disposed on the edges of both said mounting tongues and said cross-member flanges.
 6. The wine barrel rack and support system of claim 1, wherein said chocks are disposed on said cross-member flanges.
 7. The wine barrel rack and support system of claim 1, wherein said wedge plates are planar metal plates.
 8. The wine barrel rack and support system of claim 1, wherein said single-barrel cradles are arcuate.
 9. The wine barrel rack and support system of claim 8, wherein said single-barrel cradles have a radius slightly larger than that of a 60-gallon wine barrel as measured between the quarter hoop and head hoop circumferences of the barrel.
 10. The wine barrel rack and support system of claim 9, wherein said single-barrel cradles include mounting tongues are defined by slots cut into said upper edge and said lower edge.
 11. The wine barrel rack and support system of claim 1, wherein said single-barrel cradles are sized to span between adjacent barrels in the same level as separated by the spacing between adjacent barrels disposed on said ground level rack assembly.
 12. The wine barrel rack of claim 1, wherein said ground level rack assemblies include end structure to connect to adjoining ground level rack assemblies.
 13. The wine barrel rack of claim 1, wherein said cross-member flanges are bolting plates affixed to said ground level rack assembly and said single-barrel cradles using nuts and bolts.
 14. The wine barrel rack of claim 1, wherein said cross-member flanges are welded to said ground level rack assembly and said single-barrel cradles.
 15. The wine barrel rack and support system of claim 14, wherein said wedge plates include upper mounting tongues onto which said chocks are disposed.
 16. The wine barrel rack and support of claim 14, wherein said wedge plates include upper and lower mounting tongues on which said chocks are disposed.
 17. The wine barrel rack and support system of claim 14, wherein said mounting flanges and said cross-member flanges are approximated in a side-by-side layer and said chocks are disposed on the edges of both said mounting tongues and said cross-member flanges.
 18. The wine barrel rack and support system of claim 14, wherein said chocks are disposed on said cross-member flanges.
 19. A method of stacking barrels for wine and spirits production and storage, comprising: providing a ground level rack assembly that includes: first and second ground level side rails oriented generally parallel to one another, each of the first and second ground level side rails fabricated from sheet metal panels, having an upper bend forming a flange and a lower bend forming a flange, and having a plurality of upper cut outs shaped and sized to accommodate a portion of a wine barrel; a plurality of elongate cross-members disposed between and connecting the first and second ground level side rails, the cross members having an elongate tubular portion with first and second ends, and cross-member flanges disposed on each of the first and second ends; providing at least two upper level barrel cradles, each including first and second wedge plates affixed to at least two of the cross-members at the cross-member flanges, the wedge plates having an upper edge and a lower edge, and resilient mounting chocks disposed on either or both of the cross-member flanges and the wedge plates; wherein the first and second ground level side rails and the upper level barrel cradles each have a disassembled/nested configuration for storage and transport and an assembled configuration for supporting a plurality of wine barrels; assembling at least one ground level rack assembly; assembling at least one upper level barrel cradle; placing a plurality of barrels on the ground level rack assembly, such that there is at least one pair of adjacent barrels on the ground level rack assembly; placing at least one upper level barrel cradle between the at least one pair of adjacent barrels; and placing a barrel atop the at least one upper level barrel cradle.
 20. The method of claim 19, further including the step of seismically securing the barrel placed on the at least one upper level barrel cradle with a tie down strap.
 21. A wine barrel rack and support system, comprising: at least two upper level barrel cradles, each including first and second wedge plates affixed to at least two of the cross-members at the cross-member flanges, the wedge plates having an upper edge and a lower edge; and resilient mounting chocks disposed on either or both of the cross-member flanges and the wedge plates.
 22. The wine barrel rack and support system of claim 21, further including: a ground level rack assembly including first and second ground level side rails oriented generally parallel to one another, each of the first and second ground level side rails fabricated from sheet metal panels, having an upper bend forming a flange and a lower bend forming a flange, and having a plurality of upper cut outs shaped and sized to accommodate a portion of a wine barrel; and a plurality of elongate cross-members disposed between and connecting the first and second ground level side rails, the cross members having an elongate tubular portion with first and second ends, and cross-member flanges disposed on each of the first and second ends; wherein the first and second ground level side rails and the upper level barrel cradles each have a disassembled/nested configuration for storage and transport and an assembled configuration for supporting a plurality of wine barrels.
 23. The wine barrel rack and support system of claim 22, further including resilient mounting chocks disposed on either of the cross-member flanges and the wedge plates.
 24. An wedge plate comprising: a wedge plate body having a first end and a second end, a first wedge body axis passing from the first end to the second end and a second wedge body axis perpendicular to the first axis; a first upper barrel contact surface and a second upper barrel contact surface projecting upward from an upper surface of the wedge plate body, the first upper barrel contact surface disposed near the first end and the second upper barrel contact surface disposed near the second end, a first end contact surface axis passing through the first upper barrel contact surface and a second end contact surface axis passing through the second upper barrel contact surface, the first end contact surface axis and the second end contact surface axis lying in a same plane as the first wedge body axis and the second wedge body axis and angled inward such that they intersect the second wedge body axis and each other above the upper surface; a first lower barrel contact surface and a second lower barrel contact surface projecting downward from a lower surface of the wedge plate body opposite the upper surface, the first lower barrel contact surface disposed near the first end and the second lower barrel contact surface disposed near the second end, the first lower barrel contact surface being directed approximately opposite the first upper barrel contact surface along the first end contact surface axis, and the second lower barrel contact surface being directed approximately opposite the second upper barrel contact surface along the second end contact surface axis.
 25. A wedge plate as in claim 24, wherein the wedge plate body has a substantially planar shape.
 26. A wedge plate as in any of claims 24 to 25, wherein the wedge plate body has a curved shape with mirror image symmetry about the second body axis.
 27. A single barrel cradle comprising two wedge plates as in any of claims 24 to 26 and at least on cross member attached to the two wedge plates at opposite ends of the at least one cross member, the single barrel cradle being configured to support a single upper tier barrel contacting the first upper barrel contact surface and the second upper barrel contact surface on each of the two wedge plates and being supported by two lower tier barrels, a first of the two lower tier barrels contacting the first lower barrel contact surface on each of the two wedge plates and a second of the two lower tier barrels contacting the second lower barrel contact surface on each of the two wedge plates. 